Service Manual Self-Contained Crescent Cuber Models KM-230BAJ KM-300BAJ, BWJ hoshizakiamerica.
WARNING Only qualified service technicians should install and service the appliance. To obtain the name and phone number of your local Hoshizaki Certified Service Representative, visit www.hoshizaki.com. No service should be undertaken until the technician has thoroughly read this Service Manual. Failure to service and maintain the appliance in accordance with this manual will adversely affect safety, performance, component life, and warranty coverage and may result in costly water damage.
IMPORTANT This manual should be read carefully before the appliance is serviced. Read the warnings and guidelines contained in this manual carefully as they provide essential information for the continued safe use, service, and maintenance of the appliance. Retain this manual for any further reference that may be necessary. CONTENTS Important Safety Information...........................................................................................4 I.
5. Harvest Pump Timer.......................................................................................35 6. Freeze Timer...................................................................................................35 7. Pump-Out/Drain Selector................................................................................36 8. Harvest Promotion Control..............................................................................36 9. Refill Counter ................................................
Important Safety Information Throughout this manual, notices appear to bring your attention to situations which could result in death, serious injury, damage to the appliance, or damage to property. WARNING Indicates a hazardous situation which could result in death or serious injury. NOTICE Indicates a situation which could result in damage to the appliance or property. IMPORTANT Indicates important information about the installation, use, and care of the appliance.
WARNING, continued • The appliance is not intended for use by persons (including children) with reduced physical, sensory, or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety. • Young children should be properly supervised around the appliance. • Do not climb, stand, or hang on the appliance or appliance door or allow children or animals to do so.
I. Construction and Water/Refrigeration Circuit Diagram A. Construction 1.
2.
3.
9 Cube Guide Evaporator Spray Tube Pump Motor Water Tank Water Circuit Refrigerant Circuit Float Switch Water Valve Drain Thermistor Drain Valve Cleaning Valve Water Supply Expansion Valve Suction Line Discharge Line Compressor Drier Access Valve Insulation Tube Fan Condenser Hot Gas Valve Strainer High Pressure Switch B. Water/Refrigeration Circuit Diagram 1.
Cube Guide Evaporator Spray Tube 10 Pump Motor Water Tank Water Circuit Refrigerant Circuit Float Switch Water Valve Drain Thermistor Drain Valve Cleaning Valve Water Supply Expansion Valve Suction Line Discharge Line Compressor Drier Access Valve Insulation Tube Fan Condenser Hot Gas Valve Strainer High Pressure Switch 2.
Cube Guide Evaporator Spray Tube 11 Pump Motor Float Switch Water Circuit Refrigerant Circuit Water Tank Water Valve Drain Thermistor Drain Valve Cleaning Valve Water Supply Water Supply Expansion Valve Suction Line Hot Gas Valve Strainer High Pressure Switch Discharge Line Compressor Drier Drain Access Valve Insulation Tube Water Condenser Water Regulating Valve 3.
When in the “SERVICE” position, the control switch supplies power to the service switch and the machine is in service mode. The service switch has three positions: “DRAIN”, “CIRCULATE”, and “WASH”. See the information below for details of each function. DRAIN Power is supplied to the pump and drain valve. This drains the water tank. CIRCULATE Power is supplied to the pump only. This operation can be used to circulate cleaner for extended periods of time over the outside surface of the evaporator.
ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF ON OFF WATER VALVE DRAIN VALVE CLEANING VALVE FLOAT SWITCH BIN CONTROL SWITCH RELAY: X1 (COMP) RELAY: X2 (HV/FM) RELAY: X3 (PM) RELAY: X4 (WV) RELAY: X6 (DV) ON OFF ON OFF ON OFF 1°C 9°C ON OFF HOT GAS VALVE [KM-230BAJ] 30sec [KM-300BAJ/BWJ] 10sec PUMP MOTOR *KM-230BAJ, 300BAJ FAN MOTOR COMPRESSOR THERMISTOR POWER SWITCH PART NAME 13 CONTROLLER BOARD 5 sec 10 or 30sec HARVEST CYCLE (INITIAL) Max 6
3. Details The steps in the sequence are as outlined below. When power is supplied, a 5 second delay occurs at startup. Note that the order of the LEDs from the outer edge of the board is 5, 6, 8, 4, 7. a) One Minute Fill Cycle LED 8 is on. WV opens and the fill period begins. After 1 minute, the board checks for a closed F/S. If F/S is closed, the harvest cycle begins. If not, WV will remain energized through additional 1 minute cycles until water enters the sump and F/S closes.
the control board setting, pump-out cycle occurs every cycle, or every 2nd, 5th, or 10th cycle (S1 dip switch 5 & 6). e) Normal Harvest Cycle LEDs 5, 6, and 8 are on. Comp continues to run, HGV remains open and WV opens. As the evaporator warms, the thermistor reaches 48°F (9°C). The control board then receives the thermistor's 3.9 kΩ signal and starts the harvest timer.
B. Service Diagnosis WARNING • The appliance should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. • Risk of electric shock. Control switch in "OFF" position does not de-energize all loads. Use extereme caution and exercise safe electrical practices. • Moving parts (e.g., fan blade) can crush and cut. Keep hands clear. • Before servicing the appliance, move the control switch to the “OFF“ position and unplug the appliance.
4) Initial Harvest Cycle – The inlet water valve remains energized, contactor coil energizes to start the compressor (and fan motor on a remote condenser unit), and the hot gas valve energizes. The evaporator warms and the thermistor senses 48°F (9°C). The control board then receives the thermistor’s 3.9 kΩ signal and turns operation of harvest over to the harvest timer. The timer completes counting (1 to 3 minutes). The unit then cycles to freeze.
C. Control Board Check Before replacing a control board that does not show a visible defect and that you suspect is bad, always conduct the following check procedure. This procedure will help you verify your diagnosis. Alarm Reset: If CB is in alarm (beeping), press the “ALARM RESET” button on CB while CB is beeping. WARNING! Risk of electric shock. Care should be taken not to touch live terminals. Once reset, the icemaker starts at the 1-minute fill cycle. For audible alarm information, see “III.B.
machine to complete the freeze cycle and the following harvest cycle before shutting down the machine. When the bin control is activated, the “POWER OK” LED flashes. There is a delay before the shutdown sequence begins. The delay varies depending on the cycle the icemaker is in at the time of activation. For details, see the table below.
WARNING CHOKING HAZARD: Ensure all components, fasteners, and thumbscrews are securely in place after the icemaker is serviced. Make sure that none have fallen into the ice storage bin. 1) Remove the louver. Move the control switch to the “OFF” position, then unplug the appliance. 2) Remove the water tank (see “IV. C. WATER TANK“). The bin control switch is located as shown below when viewed from the front. Bin Control Switch Fig. 1 3) Remove the top panel and the rear panel.
7) Wipe down MBC with a mixture of 1 part of Hoshizaki “Scale Away” and 25 parts of warm water. Rinse the parts thoroughly with clean water. 8) Refit the removed parts in the reverse order of the removal procedure. 9) Plug in the appliance. Legend: MBC–mechanical bin control E. Float Switch Check and Cleaning FS is used to determine that there is sufficient water in the water tank after the 1-min. fill cycle and after each harvest cycle.
11) Disconnect the connector of the FS lead. 12) Check for continuity across FS leads. With the water tank full, FS should be closed. If FS is closed and the icemaker will not switch from the 1-min. fill cycle to the initial harvest cycle, replace CB. If FS is open, confirm that the water tank is full. If the water tank is not full, check the water supply, water filters, and inlet water valve. If the water tank is full, follow the steps in “II.E.2. Float Switch Cleaning.” After cleaning FS, check it again.
7) Replace FS in its correct position and secure it with the two screws. Then connect FS connector. 8) Replace the right side panel, rear panel and top panel in their correct positions. 9) Plug in the appliance, then move the control switch to the “ICE” position. Legend: CB–control board; FS-float switch F. Thermistor Check A thermistor (semiconductor) is used as a harvest control sensor and anti-slush sensor. The resistance varies depending on the suction line temperatures.
G. Diagnostic Tables 1. No Ice Production PROBLEM [1] The icemaker will not start. POSSIBLE CAUSE a) Power Supply 1. OFF position. 2. Loose connections. 3. Bad contacts. 4. Voltage too high. b) Fuse (inside fused disconnect, if any) c) Control Switch d) Bin Control Switch e) High Pressure Control f) Transformer g) Wiring to Control Board h) Thermistor i) Hot Gas Solenoid Valve j) Water Supply Line k) Inlet Water Valve l) Control Board 5. Unplugged. 1. Blown. 1. OFF or SERVICE position. 2.
PROBLEM [2] Water continues to be supplied, and the icemaker will not start. [3] Compressor will not start or operates intermittently. POSSIBLE CAUSE a) Float Switch 1. Connector disconnected. 2. Leads open or defective switch. 3. Float does not move freely. b) Control Board 1. Defective. a) Control Switch 1. SERVICE position. 2. Bad contacts. b) High Pressure 1. Dirty air filter or condenser. Control 2. Ambient temperature too warm. 3. Refrigerant overcharged. 4. Fan not operating. 5.
PROBLEM [4] Water continues to be supplied in freeze cycle. [5] No water comes from Spray Tubes. Water Pump will not start, or freeze cycle time is too short. POSSIBLE CAUSE a) Inlet Water Valve 1. Diaphragm does not close. b) Control Board 1. Defective. a) Water Supply Line 1. Water pressure too low and water level in water tank too low. 1. Dirty mesh filter or orifice and water level in water tank too low. 1. Water leaks.
2. Freeze-Up Defrost and clean the icemaker prior to diagnosing freeze-up. Fill out a freeze-up check list. See the Hoshizaki America Technician’s Pocket Guide or contact your local distributor for a copy of the freeze-up checklist. PROBLEM [1] Freeze cycle time is too long. POSSIBLE CAUSE a) Float Switch 1. Leads shorted or defective switch. 2. Float does not move freely. b) Inlet Water Valve 1. Diaphragm does not close.
3. Low Ice Production PROBLEM [1] Freeze cycle time is long. [2] Harvest cycle time is long. POSSIBLE CAUSE REMEDY a) See chart 1 - [3] and check dirty air filter or condenser, ambient or water temperature, water pressure, water regulating valve (water-cooled model), and refrigerant charge. b) See chart 2 - [1] and check float switch, inlet water valve, and control board.
5. Other PROBLEM POSSIBLE CAUSE [1] Icemaker will a) Bin Control Switch 1. Completely disconnected not stop when and dropped inside bin. bin is filled with 2. Detector broken. ice. 3. Detector out of position. 4. Defective reed switch. b) Control Board [2] Abnormal noise a) Pump Motor b) Fan Motor c) Compressor d) Refrigerant Lines [3] Ice in Storage Bin often melts. a) Bin Drain 5. Reed switch out of position. 6. Magnet disconnected from detector. 1. Defective. 1. Bearings worn out. 1.
III. Controls and Adjustments * A HOSHIZAKI exclusive solid-state control is employed in crescent cubers. * All models are pretested and factory-adjusted. NOTICE • Fragile, handle very carefully. • The control board contains integrated circuits, which are susceptible to failure due to static discharge. It is especially important to touch the metal part of the icemaker when handling or replacing the control board. • Do not touch the electronic devices on the control board or the back of the control board.
A. Control Board Layout 1. Control Board Layout "H" Control Board • Relay LEDs (6) (indicate which relays are energized as listed below) • K7 Connector Transformer • LED 5 (X1 Relay) Compressor (Comp) Fan Motor-Remote (FMR) • LED 6 (X2 Relay) Hot Gas Valve (HGV) Fan Motor (FM) (FM offLine when LED(LLV) on) Liquid Valve (FM and LLV off when LED on) • K3 Connector Power Relay Magnetic Contactor • "POWER OK" LED (Lights when power is supplied to the board. Flashes when bin control is activated.
B. LED Lights and Audible Alarm Safeties The control board includes LED indicator lights, audible alarm safeties, and an output test feature. The “POWER OK” LED indicates control voltage and will remain on unless a control voltage problem occurs. The “POWER OK” LED flashes continuously when the bin is full and DV energizes for a maximum of 5 minutes to drain the water tank. At startup, a 5 second delay occurs to stabilize the circuit.
C. Settings and Adjustments NOTICE Dip switches are factory set. Failure to maintain factory settings may adversely affect performance and warranty coverage. 1. Default Dip Switch Settings The dip switch is factory-adjusted to the following positions: S1 Dip Switch No. 1 2 3 4 KM-230BAJ OFF OFF OFF OFF KM-300BAJ OFF OFF OFF OFF KM-300BWJ OFF OFF OFF OFF S2 Dip Switch No.
timer is factory set, and generally no adjustment is required. However, a setting longer than the factory setting may be advised in cases where the drain provided at harvest needs to be prolonged for extra cleaning. Before changing this setting, contact Hoshizaki Technical Support at 1-800-233-1940 for recommendations. Keep in mind that setting the harvest timer to a longer setting decreases 24-hour production.
Dip Switch Setting No. 5 No. 6 OFF OFF ON OFF OFF ON ON ON Frequency every cycle every 2 cycles every 5 cycles every 10 cycles 5. Harvest Pump Timer (S1 dip switch 7 & 8) The harvest pump timer allows the water valve to close and the pump motor to circulate water in the tank during the final part of harvest. The water valve is open during harvest for a maximum of 6 minutes or the length of harvest minus 0, 10, 30, or 50 seconds (determined by the harvest pump timer setting), whichever is shorter.
7. Pump-Out/Drain Selector (S2 dip switch 1) The pump-out/drain selector setting determines whether the pump motor energizes (pump-out) or stays off (drain) after a 2-second delay at the beginning of the pump-out cycle or at shutdown. Regardless of the pump-out/drain selector setting, the drain valve energizes after a 2-second delay at the beginning of the pump-out cycle or at shutdown.
S2 Dip Switch Setting No. 4 OFF ON Harvest Completion Detection Control Deactivated Activated 11. Overfreeze Detection Control (S2 dip switch 5) Do not adjust. This must be left in the factory default position or the unit will not operate properly. It is deactivated on the KM-230BAJ and KM-300BAJ/BWJ. When activated, the thermistor detects the temperature of the evaporator outlet to find overfreeze in a harvest cycle and at the beginning of a freeze cycle.
S2 Dip Switch Setting No. 6 OFF ON Anti-Slush Control Activated (Ver. 1.1) Activated (Ver. 2.0) 13. Control Board Replacement The dip switches should be adjusted to the factory default settings as outlined in this manual. D. Switches Two different control switches are used for operation. They are located on the right side of the control box which becomes accessible when the front louver is removed. The upper is the control switch, and the lower is the service switch. 1.
2) CIRCULATE When the service switch is active and placed in the “CIRCULATE” position, power is supplied to the pump only. This operation can be used to circulate cleaner for extended periods of time over the outside surface of the evaporator. 3) WASH This machine utilizes a solenoid operated wash (bypass) valve. When the service switch is active and placed in the “WASH” position, power is supplied to the pump and cleaning valve.
IV. Refrigeration Circuit and Component Service Information WARNING • This appliance should be diagnosed and repaired only by qualified service personnel to reduce the risk of death, electric shock, serious injury, or fire. • To reduce the risk of electric shock, do not touch the control switch or plug with damp hands. Make sure the control switch is in the "OFF" position before plugging in or unplugging the appliance.
1. Refrigerant Recovery The icemaker is provided with a low-side refrigerant access valve. Using proper refrigerant practices, recover the refrigerant from the access valve and store it in an approved container. Do not discharge the refrigerant into the atmosphere. After recovery is complete, install a proper, permanent high-side access valve. 2. Brazing WARNING • R-404A itself is not flammable at atmospheric pressure and temperatures up to 176°F (80°C). • R-404A itself is not explosive or poisonous.
IMPORTANT The vacuum level and vacuum pump may be the same as those for current refrigerants. However, the rubber hose and gauge manifold to be used for evacuation and refrigerant charge should be exclusively for POE oils. 2) Turn on the vacuum pump. Open the gauge manifold valves. Never allow the oil in the vacuum pump to flow backwards. 3) Allow the vacuum pump to pull down to a 29.9” Hg vacuum. Evacuating period depends on pump capacity.
Hot Gas Valve • Replace the strainer if applicable. • Use copper tube of the same diameter and length when replacing valve lines. Pump Motor Install a new capacitor. Fan Motor Install a new capacitor. Thermistor • Attach the new thermistor to the same location on the previous thermistor. • Smoothly fill the recessed area of the thermistor holder with high thermal conductive type sealant.
D. Separator IMPORTANT • The front separator and rear separator are attached to the evaporator bracket with different lengths of pins. The front separator pins (10.7 mm) are longer than the rear separator pins (8.8 mm). Do not misplace the front and rear separators. • Do not attach the separators upside down or inside out. Make sure that the side printed with “THIS SIDE UP” faces up, and the side printed with “EVAPORATOR SIDE” faces the evaporator.
4) Disconnect the silicone hose from the spray tube, and remove the spray tube from the evaporator bracket. 5) Remove the front separator by pushing the pins inserted into both sides of the evaporator bracket toward the center. See Fig. 8. Note: Be careful not to break the pins. 6) The rear separator is hooked on the groove in the evaporator bracket. Remove the rear separator by lifting it up and down. See Fig. 8. 7) Refit the separators in the reverse order of the removal procedure.
F. Adjustment of Water Regulating Valve (Water-Cooled Model) The water regulating valve (also called "water regulator") is factory-adjusted. No adjustment is required under normal use. Adjust the water regulating valve, if necessary, using the following procedures. 1) Prepare a thermometer to check the condenser drain temperature. Attach a pressure gauge to the high-side line of the system. 2) Five minutes after a freeze cycle starts, confirm that the thermometer reads 104°F to 115°F (40°C to 46°C).
V. Maintenance The appliance must be maintained in accordance with the instruction manual and labels provided. WARNING • Only qualified service technicians should service the appliance. • To reduce the risk of electric shock, do not touch the control switch, service switch, or plug with damp hands. Make sure the control switch is in the "OFF" position before plugging in or unplugging the appliance.
VI. Preparing the Appliance for Periods of Non-Use NOTICE • During extended periods of non-use, extended absences, or in sub-freezing temperatures, follow the instructions below to reduce the risk of costly water damage. • To prevent damage to the water pump, do not leave the control switch in the “SERVICE” position for extended periods of time when the water tank is empty. During extended periods of non-use, extended absences, or in sub-freezing temperatures, follow the instructions below.
4) Close the door. 5) Replace the louver in its correct position. 6) Close the icemaker water supply line drain valve. 3. On water-cooled model only, remove the water from the water-cooled condenser: 1) Make sure the control switch is in the “OFF” position and the appliance is unplugged from the electrical outlet. 2) Remove the top and left side panels. 3) Close the condenser water supply line shut-off valve. If connected to a closed loop system, also close the condenser return line shut-off valve.
VIII. Technical Information A. Specification Data 1. KM-230BAJ SPECIFICATION NO. ISSUED:06/02/2017 Revision 1 ITEM: HOSHIZAKI CRESCENT CUBER MODEL: KM-230BAJ AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day ( kg/day ) Reference without *marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) WATER gal./24HR (gal./100 lbs.) ENERGY STAR 3.
2. KM-300BAJ SPECIFICATION NO. ISSUED:06/02/2017 Revision 1 ITEM: HOSHIZAKI CRESCENT CUBER MODEL: KM-300BAJ AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day ( kg/day ) Reference without *marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) WATER gal./24HR (gal./100 lbs.) ENERGY STAR 3.
3. KM-300BWJ SPECIFICATION NO. ISSUED:06/02/2017 Revision 1 ITEM: HOSHIZAKI CRESCENT CUBER MODEL: KM-300BWJ AC SUPPLY VOLTAGE AMPERAGE MINIMUM CIRCUIT AMPACITY MAXIMUM FUSE SIZE APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day ( kg/day ) Reference without *marks SHAPE OF ICE ICE PRODUCTION PER CYCLE APPROXIMATE STORAGE CAPACITY ELECTRIC & WATER CONSUMPTION ELECTRIC W (kWH/100 lbs.) POT. WATER gal./24HR (gal./100 lbs.) COND. WATER gal./24HR (gal./100 lbs.) ENERGY STAR 3.
B. Performance Data 1. KM-230BAJ PERFORMANCE DATA ITEM: HOSHIZAKI CRESCENT CUBER ISSUED:06/02/2017 MODEL: KM-230BAJ APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day kg./day APPROXIMATE ELECTRIC CONSUMPTION WATER TEMP. (ºF/ºC) AMBIENT TEMP. (ºF/ºC) 50/10 70/21 90/32 70/21 80/27 230 215 104 98 211 186 96 84 191 170 87 77 90/32 100/38 70/21 80/27 211 209 96 95 165 161 75 73 147 130 67 59 90/32 watts APPROXIMATE WATER CONSUMPTION PER 24 HR. 100/38 70/21 80/27 90/32 57 53 51 gal.
2. KM-300BAJ PERFORMANCE DATA ITEM: HOSHIZAKI CRESCENT CUBER ISSUED:06/02/2017 MODEL: KM-300BAJ APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day kg./day APPROXIMATE ELECTRIC CONSUMPTION WATER TEMP. (ºF/ºC) AMBIENT TEMP. (ºF/ºC) 50/10 90/32 70/21 80/27 295 276 134 125 270 237 123 108 251 227 114 103 90/32 100/38 70/21 80/27 270 272 123 123 210 207 95 94 196 183 89 83 90/32 watts APPROXIMATE WATER CONSUMPTION PER 24 HR. 100/38 70/21 80/27 90/32 58 56 55 gal.
3. KM-300BWJ PERFORMANCE DATA ITEM: HOSHIZAKI CRESCENT CUBER ISSUED:06/02/2017 MODEL: KM-300BWJ APPROXIMATE ICE PRODUCTION PER 24 HR. lbs./day kg./day APPROXIMATE ELECTRIC CONSUMPTION WATER TEMP. (ºF/ºC) AMBIENT TEMP. (ºF/ºC) 50/10 70/21 90/32 70/21 80/27 265 257 120 117 255 241 116 109 241 227 109 103 90/32 100/38 70/21 80/27 255 252 116 114 230 227 104 103 215 202 98 92 460 462 463 467 "H" 476 484 486 90/32 463 470 watts APPROXIMATE WATER CONSUMPTION PER 24 HR.
C.
